Prima
Workshop Manual
P1 Single Pressure Model
P2 Twin Pressure Model
Prima P1
Prima P2
GODIVA LIMITED
A Unit of IDEX Corporation
Charles St
Warwick CV34 5LR
England
+44 (0)1926 623600
+44 (0)1926 623666
www.godiva.co.uk
[email protected]
GP/290
Issue 4, March 2014
AMENDMENT RECORD
Model: Prima, single and twin pressure models
Mod
No.
Date
Page/s
1
June
2011
March
2012
March
2012
May
2013
March
2014
All
New publication
44
2
48
Gearbox oil capacity revised to 1.2
litres
Water ring primer – 3mm lift-off gap
60
Adhesives and solvents list added
3
19
Modify information on seal
assembly installation
4
2
3
4
5
Amendment
New Issue No.
2
1
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
CONTENTS
AMENDMENT RECORD ................................................................................. 1
CONTENTS ..................................................................................................... 2
SAFETY ........................................................................................................... 5
IN OPERATION ......................................................................................................... 5
TRAINING ................................................................................................................ 5
MAINTENANCE ........................................................................................................ 5
ENVIRONMENTAL PROTECTION ................................................................................ 5
RISK ASSESSMENT .................................................................................................. 5
TRANSPORTATION AND STORAGE ............................................................................. 5
WARRANTY ............................................................................................................. 6
ASSOCIATED PUBLICATIONS .................................................................................... 6
PUMP SPECIFICATION NUMBERING ........................................................... 6
......................................................................................................................... 6
ENVIRONMENTAL PROTECTION ................................................................. 7
OPERATOR MAINTENANCE LOG ................................................................ 8
MAINTENANCE SCHEDULE .......................................................................... 9
REMOVAL & INSTALLATION ...................................................................... 10
INTRODUCTION ...................................................................................................... 10
PRECAUTIONS ....................................................................................................... 10
POST REPAIR AND ASSEMBLY ................................................................................ 10
1. SUCTION TUBE AND FRONT WEARING RING .......................................................... 11
Removal .......................................................................................................................... 11
Installation ....................................................................................................................... 11
2. LOW PRESSURE IMPELLER ................................................................................. 13
Removal .......................................................................................................................... 13
Installation ....................................................................................................................... 14
3. REAR W EAR RING ............................................................................................. 14
Removal .......................................................................................................................... 14
Installation ....................................................................................................................... 15
Removal .......................................................................................................................... 15
Installation ....................................................................................................................... 15
4. P2 ONLY - HIGH PRESSURE IMPELLER ................................................................ 16
Removal .......................................................................................................................... 16
5. P2 ONLY - HIGH PRESSURE IMPELLER - MAINTENANCE ........................................ 16
Installation ....................................................................................................................... 16
6. MECHANICAL SEAL MAINTENANCE ...................................................................... 19
Removal .......................................................................................................................... 19
Installation ....................................................................................................................... 19
7. VOLUTE BODY ................................................................................................... 21
Removal .......................................................................................................................... 21
Installation ....................................................................................................................... 21
8. LOW PRESSURE MANIFOLD AND HIGH/LOW PRESSURE FILTER HOUSING (P2) ...... 21
Removal – High/Low pressure Filter Housing ................................................................ 21
Removal – Low pressure manifold ................................................................................. 22
Removal .......................................................................................................................... 22
9. PRIMING VALVE ................................................................................................. 23
Removal .......................................................................................................................... 23
10. PRIMER SYSTEM – RECIPROCATING PISTON PRIMER ......................................... 24
2
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Removal / Maintenance .................................................................................................. 24
11. PUMP HEAD .................................................................................................... 31
Removal .......................................................................................................................... 31
Installation ....................................................................................................................... 31
12. FRONT END OIL SEAL ...................................................................................... 32
Removal .......................................................................................................................... 32
Installation ....................................................................................................................... 32
12. REAR OIL SEAL ............................................................................................... 32
Removal .......................................................................................................................... 32
Installation ....................................................................................................................... 32
13. BEARING HOUSING .......................................................................................... 32
Removal .......................................................................................................................... 32
Rebuild / Installation ........................................................................................................ 34
14. GEARBOX (OPTIONAL) ..................................................................................... 44
15. W ATER RING PRIMER (OPTIONAL) .................................................................... 46
To Remove ..................................................................................................................... 46
Maintenance ................................................................................................................... 46
To Refit............................................................................................................................ 48
16. PUMP TESTS ................................................................................................... 49
Vacuum Test ................................................................................................................... 49
Pressure Test .................................................................................................................. 49
Water Ring Primer (optional priming system) ................................................................. 49
Pressure Relief Valve (PRV) and Thermal Relief Valve (TRV) Test .............................. 50
Thermal Relief Valve Maintenance ................................................................................. 50
17. DELIVERY VALVES ........................................................................................... 53
Ball Valve Type ............................................................................................................... 53
Screw-down Type ........................................................................................................... 55
Continental Delivery Valves ............................................................................................ 56
Instantaneous Connector Servicing Procedure: ............................................................. 58
17. TIGHTENING TORQUES..................................................................................... 59
18. SPECIAL TOOLS............................................................................................... 59
19. ADHESIVES AND SOLVENTS LIST ...................................................................... 60
3
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Page intentionally left blank.
4
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
SAFETY
Please read this manual before operating the machinery.
Safety notices -
!
IMPORTANT
= non-compliance could affect safety
= in case of damage to pump
In operation
 Rotating parts must be guarded against accidental contact.

Do not insert items into the suction tube when pump is running.

Discharge hoses must not be disconnected when the unit is running.

No components must be unfastened when the unit is running.

When installing or removing the pump, suitable lifting equipment must be
used.

Suitable ear protection must be worn when pump is running – if necessary.
Training
Godiva pumps must only be operated by trained personnel.
Maintenance
The user must maintain the equipment in an operational condition, as per
regulation 5 in the Provision and Use of Work Equipment Regulations 1998.
Environmental Protection
Used oil from the pump must be disposed of in accordance with your local
regulations
Risk Assessment
It is the duty of the pump installer to make a risk assessment of their
operations when installing the pump, please contact Godiva Ltd. if assistance
is required.
Transportation and Storage
The pump is supplied mounted on a wooden pallet and covered with a triwalled cardboard box. This protection is suitable for standard methods of
freight handling using forklift trucks. No more than one pump should be
stacked on top of another. The tri-walled cardboard box is not suitable for
storage when open to the elements. The pump is sprayed internally with a
moisture inhibitor when leaving the factory, this treatment may be required if
the pump is in long term storage (6 months or more) before use. On receipt of
the pump a full inspection must be carried out, if any damage has occurred
please contact Godiva Ltd.
5
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Warranty
For all issues relating to warranty claims please contact Godiva Ltd.. Please
be prepared to quote the six figure pump serial number located on the pump
volute.
Gauges (if fitted)
Do not clean the glass surfaces of the gauges with abrasive or solvent
cleaners. These will cloud the glass surface. Use a mild detergent and water.
Associated Publications
Publication
Installation and Operation Manual
P1 Spare Parts Manual
P2 Spare Parts Manual
Part No
GP/287
GP/281
GP/258
PUMP SPECIFICATION NUMBERING
P C 1 A 20 10
601123 = typical six figure serial number
Stamped on volute body (boss at top left)
Nominal pressure in bars
Nominal flow in litres / minute x 100
A = Aluminium B = Bronze
1 = Single pressure, 2 = Twin pressure
C = Compressed air foam system fitted (option)
P = Prima series
6
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
ENVIRONMENTAL PROTECTION
It is prohibited to pour oil and other contaminants onto the ground, down
sewers, drains, or into water courses.
Dispose of lubricants through authorised waste disposal contractors, licensed
waste disposal sites, or to the waste reclamation trade.
If in doubt, contact your Local Environmental Agency for advice regarding
disposal policies.
7
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
OPERATOR MAINTENANCE LOG
Pump serial number . . . . . . . . . . . . . . . . . . . . .
Use this log to record faults, part replacements and major overhauls.
Please contact Customer Services at Godiva Ltd. prior to any proposed
return of either a single part, or a complete assembly.
Date Hours
Run
Inspection / Fault
Parts
Used
Reason For Renewal
Initial
8
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
MAINTENANCE SCHEDULE
Maintenance intervals and action required
Interval
After each use –
Every 3 months Check oil level in
bearing housing
Vacuum test
Pressure test – for
tracing location of
vacuum leak
P2 only - High pressure
filter
Every 12 months Change oil in bearing
housing
Change oil in gearbox if fitted
Every 2 years Change piston primer
seals in cover and body
Thermal Relief Valve
Test
Action required
Flush pump through
with clean water
Items Required
Supply of clean water
Remove filler/dipstick
on bearing housing to
check level
See separate
instructions on page 48
See separate
instructions on page 48
10w/40 or 15w/40
multigrade engine oil
Access to pressurised
water source
Remove the filter from
the housing and flush
with clean water
Drain oil from bearing
housing and refill with
new oil
Drain oil from gearbox
and refill with new oil
1 litre SAE10w/40 or
15w/40 multigrade
engine oil
1.2 litres BP Energol
GR XP 68 or similar
Maintenance manual
procedures page 24
Repair kits
Special tools
(contact Godiva)
See separate
instructions on page 49
9
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
REMOVAL & INSTALLATION
Introduction
Instructions particular to the repair of Godiva Prima Fire Pump series are
detailed in the following sections.
These instructions describe the complete strip-down of the pump. To reduce
unnecessary work and avoid the introduction of other issues, only dismantle
those parts necessary to effect inspection and or repair.
P1 and P2 Models – for both pumps the majority of parts are common.
Where parts are unique to the P1 or P2 pump, this is indicated in the text.
Precautions
Before carrying out repair work, take the following precautions:
o Drain the volute of water.
Post Repair and Assembly
On completion of work:
o Carry out vacuum test.
o Complete the maintenance log.
10
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
1. Suction tube and front wearing ring
Removal
1. Undo the 12 x hexagon head bolts (shown).
If necessary remove the tank to pump line, collecting head and RTP unit.
Disconnect the vacuum gauge tubing from the top of the suction tube.
To remove and replace the front wearing ring in the locating bore in the
suction cover plate, undo the 4 x cap screws and washers
Check the large internal diameter of the wearing ring in several places. If
dimension A exceeds the limit given in the table the wearing ring must be
replaced.
Pump
P1_2010 / P2_3010
P1_4010
P1_6010
Internal Ø Limit - mm
140.16 / 140.10
170.685 / 170.632
187.07 / 187.00
Pump
P2_2010 / P2_3010
P2_4010
P2_6010
Internal Ø Limit - mm
140.16 / 140.10
170.685 / 170.632
187.07 / 187.00
Ø
Installation
Installation is the reverse of removal noting:
11
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
When replacing the front wear ring apply Loctite 243 to screw threads and
torque to 12 Nm.
Insert the O ring (65097) in the O ring groove on the locating diameter on the
suction tube cover plate (shown).
O ring here
Re-connect the collecting head, vacuum gauge tubing and tank to pump line
(or blanking plates for tank to pump apertures if fitted).
12
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
2. Low Pressure Impeller
Removal
To remove and inspect the low pressure impeller, remove the suction tube
and associated parts as described in section 1. This gives direct access to the
low pressure impeller leaving the volute body in-situ.
To remove the impeller it may be necessary to fit a shaft locking screw in the
aperture provided at the rear of the bearing housing. Remove the impeller nut
and the pair of lock washers, withdraw the impeller from the keyed pump
shaft.
Check the wearing diameter on the impeller in several places. If the diameter
is less than stated in the table below, a new impeller should be fitted.
P1 Model
Pump
P1_2010 / 3010
P1_4010
P1_6010
Front Diameter A mm
139.3 mm
169.5 mm
188.6mm
Rear Diameter B mm
146.1
170.8
184.2
13
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
P2 Model
A
C
B
Pump
P2_2010 / 3010
P2_4010
P2_6010
Front Diameter A
mm
139.70 / 139.65
170.06 / 170.00
186.25 / 186.20
Rear Diameter B
mm
134.93 / 134.88
170.47 / 170.40
188.07 / 188.00
Hub Diameter C
mm
68.05 / 68.00
68.05 / 68.00
68.05 / 68.00
Installation
Apply a small amount of tallow to the bore of the low pressure impeller.
Place a new O ring into the end face groove of the impeller. Place the impeller
on the shaft and retain using a new set of locking washers. Tighten the locking
nut to a torque of 300Nm.
3. Rear Wear Ring
P1 Model
Removal
The rear wear ring is accessible when the low pressure impeller is removed.
To remove the wear ring undo the four screws and washers retaining the ring
against the pump head. The wear ring can be eased away from the pump
head by means of two screws inserted into the adjacent tappings.
Check the wearing diameters as follows –
P1_4010/6010
P1_2010/3010
14
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Pump
P1_2010/3010
P1_4010
P1_6010
ØX
144.9mm
169.5mm
183mm
Installation
When relocating the rear wear ring into the pump head, ensure the priming
port in the ring is located at the top. Secure the wear ring with the washers
and screws. Tighten to 10Nm.
P2 Model
Removal
The rear wear ring is accessible when the low pressure impeller is removed.
To remove the wear ring undo the four screws and washers retaining the ring
against the high pressure cover plate. The wear ring can be eased away from
the cover plate by means of two screws inserted into the adjacent tappings.
Check the wearing diameters as follows –
X
Y
Pump
P2_2010/3010
P2_4010
P2_6010
ØX
134.440 / 134.400
170.000 / 169.937
187.45 / 187.40
ØY
68.500 / 68.450
68.500 / 68.450
68.500 / 68.450
Installation
When relocating the rear wear ring into the cover plate, ensure the priming
port in the ring is located at the top. Secure the wear ring with the washers
and screws. Tighten to 10Nm.
15
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
4. P2 Only - High Pressure Impeller
Removal
To access the high pressure impeller the suction tube and low pressure
impeller must be removed as per sections 1 and 2.
Remove the high pressure cover plate by undoing the 12 off cap screws.
Insert 3 off M8 bolts into the extractor holes around the edge of the plate.
Screw the bolts in evenly until the plate moves forward.
Remove the cover plate and high pressure impeller. Clean the cover plate and
pump body jointing faces.
5. P2 Only - High Pressure Impeller - Maintenance
Check the high pressure impeller, pump body, mechanical seal assembly for
wear. Replace any worn parts.
Installation
Replacing the high pressure impeller requires precise setting to achieve the
rated output. If no new parts are fitted, the original shims as fitted to the pump
may be refitted and a check on clearances carried out as detailed below.
If new parts are fitted then follow this checking procedure –
Measure the depth of the high pressure counter bore in the pump body
(Dimension A). Measure the thickness of the impeller (Dimension B).
Required clearance C = (A-B)/2.
A
B
C = clearance
required both
sides of impeller
Place a 1.1mm shim pack made up of 60095 series shims onto the pump
shaft and then fit the high pressure impeller. Place a clamping spacer over the
pump shaft and securely tighten the impeller using the shaft retaining nut.
Measure the depth between the face of the impeller and the shoulder within
the pump body (Dimension X). Adjust the previously fitted shim pack until
Dimension X = C.
16
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Clamping spacer
Remove the impeller to re-fit the mechanical seal and main key on the pump
shaft – if they have been removed.
Replace the high pressure impeller on the pump shaft.
Available shims for setting the high pressure impeller Pack
Thickness
mm
0.0508
0.1016
0.127
0.1524
0.1778
0.2032
0.2286
0.254
0.2794
0.3048
0.3302
0.355
0.3810
0.4064
0.4318
0.4572
0.4826
0.508
0.5334
0.5588
0.5842
0.6096
0.635
0.6604
0.6858
0.7112
0.7366
0.7620
Pack
Thickness
inches
0.002
0.004
0.005
0.006
0.007
0.008
0.009
0.010
0.011
0.012
0.013
0.014
0.015
0.016
0.017
0.018
0.019
0.020
0.021
0.022
0.023
0.024
0.025
0.026
0.027
0.028
0.029
0.030
0.0508mm
/0.002”
Part No.
60095/01
0.127mm
/0.005”
Part No.
60095/02
0.254mm
/0.010”
Part No.
60095/03
0.3810mm
/0.015”
Part No.
60095/04
Qty 1
Qty 2
Qty 1
Qty 3
Qty 1
Qty 4
Qty 2
Qty 1
Qty 1
Qty 1
Qty 3
Qty 1
Qty 4
Qty 2
Qty 1
Qty 1
Qty 1
Qty 1
Qty 3
Qty 1
Qty 4
Qty 2
Qty 1
Qty 1
Qty 1
Qty 1
Qty 1
Qty 2
Qty 3
Qty 1
Qty 4
Qty 2
Qty 1
Qty 2
Qty 1
Qty 3
Qty 1
Qty 4
Qty 2
Qty 1
Qty 2
Qty 1
Qty 2
Qty 2
Qty 2
Qty 1
Qty 1
Qty 1
Qty 2
17
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Before replacing the high pressure cover plate, ensure the auto drain ball
bearing is moving freely in the high pressure drain valve. If the retaining plate
does have to be removed ensure the two cap screws are secured with Loctite
243 to the threads.
Replace the high pressure cover plate against the pump body. Retain with 12
off cap screws and torque to 44 Nm. Apply Molykote P37 or similar under the
head of the cap screws to prevent galling.
Place the O ring (57044) into the groove on the end of the pump shaft, and
two O rings into the grooves in the transfer tube openings in the pump body
ready to receive the low pressure manifold and high/low pressure filter
housing.
18
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
6. Mechanical Seal Maintenance
With the high pressure impeller (P2) or low pressure impeller (P1) removed
the carbon seal can be examined for wear.
If there has been excessive leakage past the carbon seal and through the
drain hole in the pump head, examine the carbon seal.
If the face of the carbon seal is scored, this will have to be replaced along with
the mating part, the silicon carbide ring located in the rear side of the HP
impeller (P2) or low pressure impeller (P1).
Removal
The carbon seal can be removed from the carrier assembly by undoing the
two screws securing the assembly to the pump body. Carefully remove the
carbon seal.
P2 pump body shown
The silicon carbide ring fitted in the high pressure impeller (P2) or low
pressure impeller (P1) can be levered out by means of a small instrument
screwdriver.
Installation
Ensure that the lapped faces are clean. Soiled faces must be cleaned with the
appropriate degreasing cleaner and soft tissue.
Ensure that the pump body and high pressure impeller (P2) are clean and free
from burrs and sharp edges.
Apply a suitable lubricant, e.g. soft soap solution (washing up liquid) to the O
ring and carefully insert the seal assembly into the pump body, lining up the
screw holes in the seal assembly with the screw holes in the pump body.
Replace the two screws and seals retaining the seal. Tighten the screws half
a turn at a time so the seal assembly is pulled squarely into the pump body.
Ensure the screws are fully secured.
19
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Ensure the carbon face is clean and free from grease, if not use a degreasing
cleaner and soft tissue. Apply clean water to the carbon face.
Fit the opposite seal mating ring assembly into the high pressure impeller bore
using fitting tool 60275/08. Ensure the face of the mating ring is fitted squarely
in the impeller housing within 0.1mm. Use a soft soap solution on seal cup to
ease fitting.
Carefully fit the high pressure impeller onto the shaft and continue with pump
build.
20
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
7. Volute Body
It is unlikely that the volute body will need to be removed during normal
service. But if removal is required Removal
Remove the suction tube as in section 1.
The volute is mounted to the pump body by 12 off capscrews. The volute may
be mounted on either standard rotation or reverse rotation pumps, and must
be fitted the correct way for the rotation of the pump. The arrow cast on the
volute will point in the direction of rotation.
Installation
Installation is a reversal of the removal process.
8. Low Pressure Manifold and High/Low Pressure Filter Housing (P2)
The low pressure manifold and the high/low pressure filter housing are
attached to the top of the volute.
Removal – High/Low pressure Filter Housing
P2 only – first disconnect the high pressure pump discharge connections
together with gauge, thermal relief valve and foam connections.
The high/low pressure filter housing is removed by undoing the six bolts
securing the housing to the manifold below.
21
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Below the high/low pressure filter housing, the low pressure manifold is
secured to the volute by five bolts.
The filter in the high/low pressure housing is designed to prevent large
particles from entering the high pressure stage. During pump operation in low
pressure mode and at any time the pressure relief valve is open, a flow of
water is directed across the filter helping to flush the exterior of the filter.
The change over valve is clamped between the filter housing and the bypass
connector housing and is retained by four off bolts. Also constrained between
the two housings is the cylindrical pressure relief valve and sealed on its
outside diameter by two O rings. This valve contains a strong internal spring
and must not be stripped down. It is reinstalled with its open end towards the
filter housing. It is retained by an external circlip.
Removal – Low pressure manifold
P1 only The low pressure manifold, with filter housing, is attached to the top
of the volute.
Removal
To remove this entire assembly disconnect the pressure gauge connections
together with any foam connection options that may be fitted.
22
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
The low pressure manifold is secured to the volute by five bolts.
The filter on the low pressure manifold is designed to filter water that can be
used for ancillary devices, e.g. gearbox cooling. The filter can be unscrewed
and removed for cleaning in running water.
9. Priming Valve
Removal
The Prima pump uses a single priming valve attached to the rear of the pump
body and connected to the piston primers by two short hose lengths.
23
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
A
A
B
B
C
A
A
A
C
D
G
E
F
A
E
A
A
A
A
A
A
G
A
A
A
A
1. Disconnect the priming pipes (A) from the priming valve.
2. The priming valve can be removed from the pump as a complete
assembly by undoing the nuts on the two studs (B).
3. To dismantle the priming valve undo the two bolts (D)
Remove the priming valve cover and discard the diaphragm (C).
4. Remove the screw (F) from the piston and separate the piston parts.
Discard the seal (G).
5. Discard the ‘O’ ring (E).
6. Inspect all parts for signs of wear or damage, check that they are in
good condition. Replace damaged parts if necessary.
7. Assemble parts in reverse order, making sure that a new ‘O’ ring (E),
seal (G) and diaphragm (C) are installed. Tighten bolts (D) to complete
the unit.
8. Install the priming valve assembly to the pump and secure with the nuts
(B) and washers.
9. Connect the priming pipes (A) to the priming valve
10. Primer System – Reciprocating Piston Primer
Removal / Maintenance
The reciprocating piston primer system features two identical pistons located
each side of the pump shaft in the bearing housing. Both primers are
connected by a flexible hose to the priming valve and through this to the
suction tube.
24
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
A
A
F
B
D
B
E
C
C
C
End Cover
1. Disconnect the hose (A).
2. Remove four bolts (B) and washers. Remove the cover (C).
3. The rubber inlet (D p/n 65009) and outlet (E p/n 65008/002) valves must
be changed.
4. To replace the valves, remove the screw (F). Remove the valves from the
cover.
5. Clean the inside of the cover.
6. Install new valves in the cover. Apply Loctite 380e to the threads of the
screw (F). Avoid placing Loctite on the underside of the screw head.
7. Secure the valves with the screw.
25
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Primer Piston and Cylinder
These assemblies contain a number of seals that should be replaced.
N
M
A
A
P
H
K
R S
L
J
G
The piston (G) and cylinder liner (H) assembly comprise two ‘O’ rings (J p/n
65134) and K p/n 61097) and a water seal (L p/n 65119).
1. Replace the two ‘O’ rings and water seal.
2. The water seal and O ring are best replaced using the Godiva special tool
P/n 65239/65240 Piston Seal Assembly Tool. This helps to slide the water
seal over the edge of the piston.
3. O ring 65134 is placed in the groove of the piston, this is a loose fit. Cone
locator 65239 sits on top of the piston, using the piston ring edge as a
location guide.
4. Water seal 65119 is placed over the locator at the narrow end. The water
seal is placed with the O ring groove facing downwards, so the already
fitted O ring can be accommodated. A small amount of water can be used
as lubrication around the seal and locator surfaces.
5. Place the seal expander 65240 over the cone with the outer edge
pressing down on the water seal.
6. Press down on the seal expander to force the water seal down towards
the piston groove. A final push will force the water seal into the piston
groove resting on top of the O ring already in the groove.
7. The seal expander and cone locator are now removed.
8. O ring K (p/n 61097) rests in a groove on the outside of the cylinder liner
H (p/n 65006/002) and can hand fitted.
26
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
A
A
9. The cylinder body (M) assembly has an outer ‘O’ ring (N) and an inner
seal arrangement (P) that comprises three ‘o’ rings, two shaft seals and a
wiper carrier. These items are secured in the cylinder bore with a retaining
disc (R) and circlip (S).
10. Replace O ring N (p/n 61097) on the cylinder M by pressing the O ring
into the groove.
11. To replace the inner seal arrangement P a set of special tools are
available to assist correct fitting.
12. First insert the seal (p/n 65159) with its O ring (p/n 65160). It is useful to
use the piston shaft as a guidance tool inserted into the cylinder at the
reverse side to the working position. Note how the O ring is pointing
downwards when inserting in the cylinder.
Seal (65159) with O
ring (65160) placed
into cylinder recess
and hand pushed to
bottom
Piston inserted into
reverse side of cylinder
to act as seal guide
A
A
27
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
13. Next - the second group of seals (p/n 52816, 65161, 65162) can be
prepared for fitting. These three parts locate onto the wiper carrier (p/n
65158/001), a component that should not need replacing.
This picture shows how the seals assemble on the carrier.
A
B
C
D
A = O ring p/n 52816
B = Wiper carrier p/n 65158/001
C = seal p/n 65161
D = O ring p/n 65162
The complete assembly is
placed in the cylinder
using the piston shaft as a
location guide.
Apply a smear of general purpose grease to the O ring A, to assist
inserting the assembly into the cylinder.
14. When inserting the seal assembly into the cylinder a suitable press can be
used to push the seal to the bottom of the cylinder, using the special tools
and retaining disc (p/n 65157) described in section 16 – but without
inserting the circlip
15. The seal assembly is retained in the cylinder body by a retaining disc and
circlip.
16. To fully insert the seals and O rings use the special tools as indicated in
this diagram -
28
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
16. Cylinder support tool (p/n 65466) is used to raise the cylinder a short
height.
17. Insert the retaining disc (p/n 65167) to rest on top of the previously
inserted seals and O ring assemblies.
A
A
17. Place the circlip fitting tool (p/n 65436) over the end of piston shaft and
resting on the cylinder casting.
18. Insert the circlip (p/n 60914) into the circlip fitting tool.
19. Place the Circlip Drift tool inside the fitting tool to rest on the circlip. By
applying pressure to the fitting tool, using a suitable manual press, the circlip
will be pushed down until it fits into the groove inside the cylinder liner. This
secures and retains the seal assemblies, as below.
29
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
20. The piston can now be removed from the cylinder and re-assembled to the
cylinder in the correct orientation. The manual press can also be used to force
the piston through the seal arrangement until the piston rests in the bottom of
the cylinder.
The complete assembly can now be placed back onto the bearing housing
with the piston shaft placed to connect with the pump shaft yoke inside.
If only one cylinder assembly is removed for repair, the cylinder in place will
maintain the position of the yoke. If both cylinders are removed, use a guide
rod inserted into the yoke to help connect the yoke and the piston shaft.
The cylinder/piston assembly will then slide over the guide rod and connect
with the yoke.
30
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
The screw (p/n 65169) and bonded seal (p/n MS133/8) are inserted to secure
the piston to the yoke. If the seal is being used again, apply Loctite 243
around the screw head to secure the bolt. Tighten to a torque of 20Nm.
21. Install the priming valve cover (C) and secure with the four screws (B) and
washers.
22. Connect the hose (A) to the priming valve.
A
A
11. Pump Head
The main reason for removing the pump head is to gain access to the bearing
housing. But the front oil seal mounted on the bearing housing can be
accessed without removing the pump head.
Removal
Remove the low pressure manifold, volute body, impellers, cover plate and
mechanical seal assembly, as detailed in the previous sections.
Unscrew the six nuts and washers retaining the pump head to the bearing
housing. Using a hide faced hammer, tap around the pump head until it is
separated from the bearing housing.
Installation
Installation is a reversal of the removal process.
31
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
12. Front End Oil Seal
Removal
To access the front end oil seal, remove the low pressure impeller, cover
plate, high pressure impeller and mechanical seal and other relevant sections.
Remove the seal housing by undoing the four cap screws.
Installation
When re-fitting, insert a new oil seal into the seal housing. Secure the seal
housing with the four cap screws.
12. Rear Oil Seal
Removal
For access to the rear end shaft and oil seal it is necessary to disconnect the
drive shaft from the pump drive flange and drain oil from the bearing housing.
Installation
When re-fitting, insert a new oil seal into the seal housing. Secure the seal
housing with the four cap screws.
13. Bearing Housing
The following section will only be necessary if worn or damaged bearings or a
faulty clutch are suspected.
Removal
Remove from the bearing housing all the assemblies mentioned in previous
sections, leaving the bearing housing as a separate module. Drain the bearing
housing of all oil.
Remove the front and rear oil seal housings. Lightly tap the shaft assembly
with a hammer, forwards from the rear (drive flange end), the entire assembly
will move forward and free of the bearing housing.
The shaft assembly can be dissembled by reversing the assembly process
described below.
To remove the components on the shaft it is necessary to remove the bearing
inner race (at the drive flange end). This can be removed by using a special
extractor tool that grips the flinger assembly behind the bearing inner race.
32
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
The shaft assembly is set upright on a work bench. By turning the extractor
tool the flinger assembly is moved up the shaft and the bearing inner race is
pulled away from the shaft.
Note: the majority of the components will slide off the shaft (flinger assembly,
shims, balance weight/sliders/yoke/eccentric assembly) but the clutch
rotor/stator and two shaft bearings require careful separartion.
To remove the clutch rotor from the stator it may be necessary to lever it away
from the stator with a suitable tool.
Lever here to
remove
clutch rotor
The clutch stator can now be forced off the shaft using a suitable press tool or
tapping with a soft headed hammer around the outer edge.
33
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
The two bearings left on the shaft will require a press tool to force the shaft
away from the bearings. Support the bearings underneath and force the shaft
down and away from the bearings
.
Support bearings under here
in tool stand to allow shaft to
be forced through
This action will complete the stripping down of the shaft assembly.
Rebuild / Installation
A new shaft assembly is constructed by following these procedures –
Press two bearings (p/n 60002) onto the shaft. Apply tallow to shaft to ease
assembly. The bearings should be fitted with the large inner race facing
outwards from the bearing pair.
Place the clutch stator on a suitable support and lower the shaft and bearing
assembly into it.
34
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Fit the lip seal (p/n 60012) into the seal housing (p/n 65019/001).
Place the O ring (p/n 65171) on the seal housing.
Secure the seal housing to the clutch stator with 6 off MS164/20 screws.
Apply Loctite 243 to the threads and torque to 20Nm.
Fit the 53526 ‘O’ ring onto the outside of 65017/004 clutch stator.
35
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Place a 51355 ‘O’ ring into the 60141 seal wear ring. Smear grease between
the lips of the lip seal and insert the wear ring onto the shaft and into the lip
seal.
60141
51355
Place the shaft assembly in a locking device so that the drive end of the shaft
is uppermost.
Place the MS79/44 key into the shaft.
Place the clutch stator over the shaft, locating on the previously fitted key.
Place the clutch rotor onto the shaft to rest on top of the previously installed
stator.
36
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
There are two types of clutch rotor fixing onto the shaft –
1. Early models - with Loctite 638
2. Later models - press fit (no Loctite)
1. Using Loctite 638
Apply Loctite 638 sparingly to the outer surface of the shaft, keep the Loctite
away from the bearing below.
Also apply Loctite 638 sparingly to the inner surface of the rotor.
Place the rotor onto the shaft, aligning correctly with the shaft key, and press it
down until it rests firmly on the stator below. Allow Loctite to set.
2. Later model clutch units are held in position by pressing onto the shaft.
Loctite is not required.
37
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Turn the assembly over 180° and into a suitable press plate hole.
Press down on the shaft (low force of 20kN) until the stator is fully home.
Using a suitable press tool insert the 56949/008 DU bush into the 65021/005
eccentric drive. The bush should be pushed through the balance weight so it
is slightly below or flush with the rear face.
DU bearing slightly
below rear face of
eccentric drive
38
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Secure the clutch friction plate (part of 65017/004) to the eccentric drive using
the (3) screws and washers supplied by clutch manufacturer. Apply Loctite
243 to the threads, Tighten to a torque of 28Nm.
Then measure the distance between the surface of the friction plate and the
lower surface of the eccentric drive. The measurement will be approximately
4.0 – 4.1mm. Note this measurement.
A gap of 0.24/0.40mm is required between the clutch rotor and friction plate.
Selection of an appropriate shim from the table at the end of this section will
give the required gap. E.g. gap is 4.1mm, add .3mm for the gap, therefore a
shim of 4.4mm is required. A shim of 4.4mm is green coded. See table on
page 42.
The previously assembled eccentric drive and friction plate can now be
lowered over the shaft onto the clutch rotor face. Check the gap between the
friction plate and rotor, it should be 0.3mm.
Next proceed to add the slider bush, yoke and balance weight components.
39
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Place the first slider bush onto the shaft with the flat surface downwards.
Place the yoke over the slider bush with the straight sides in line.
Place the second slider bush over the yoke with the straight sides in line.
Place the balance weight over the second slider bush and secure it to the
eccentric drive below using two socket head screws.
40
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Now measure the distance between the top surface of the balance weight and
the shoulder on the shaft just above. Record this measurement. Deduct
0.1mm from this measurement to give the shim pack size required.
E.g Measurement is 8.4mm, minus 0.1mm, equals a shim pack of 8.3mm.
See table on page 42.
Place shims on the shaft equivalent to 8.3mm. The table on page 42 provides
the shim options. Place the flinger assembly onto the shims and check the
gap between the top shim and the flinger, gap required is 0.05-0.15mm.
Check this gap is
between 0.05 – 0.15mm
Using a suitable power supply (12V or 24V DC as appropriate), power up the
electromagnetic clutch to confirm activation, and ensure that the clutch
assembly can’t be rotated on the shaft. This confirms the presence of the
MS79/44 key and clutch operation.
41
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
The shaft assembly is now ready to be loaded into the bearing housing
Ensure that the yoke is positioned on the pump shaft assembly at mid stroke
position. This eases assembly of the shaft assembly into the bearing housing.
Load the shaft assembly into the bearing housing ensuring that the wire for
the electromagnetic clutch aligns with the slot in the face of the bearing
housing.
Place the 60007 rear bearing outer race into the back end of the bearing
housing to help support the shaft.
Secure the 65019/001 seal housing to the 65000/300 bearing housing using
(6) MS164/20 cap screws, apply Loctite 243 to the threads torque to 20Nm.
Fit the 53384/01 ‘O-ring onto the shaft underneath the rear oil seal wearing
60008.
Fit the 50682/02 oil seal into the 65094 seal housing.
Put the previously assembled 65094 seal housing on to the rear of the
bearing housing and loosely locate with (4) MS166/25 screws.
Fit the 60008 rear oil sealing wearing to centralise the rear seal housing and
tighten the (4) MS166/25 screws.
42
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Bearing Housing - Shim Details
Two sections on the shaft require shims.
1. Select shim spacer to give 0.24 / 0.40mm air gap on clutch – between
friction plate and clutch rotor.
2. Select shim spacer/s to give 0.05/0.15mm gap between balance weight and
flinger assembly to give minimum clearance for free rotation.
SHIM SPACER COMBINATION
PACK
THICKNESS
COLOUR
8.0
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
9.0
9.1
9.2
9.3
9.4
9.5
9.6
4.0
PART No
65166
BLACK
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
4.1
PART No
65166/001
WHITE
4.2
PART No
65166/002
RED
4.3
PART No
65166/003
BLUE
4.4
PART No
65166/004
GREEN
QTY 1
QTY 1
QTY 1
QTY 1
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 2
QTY 1
4.1
PART No
65166/001
WHITE
5.1
PART No
65166/006
ORANGE
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
ALTERNATIVE COMBINATION
PACK
THICKNESS
COLOUR
4.5
PART No
65166/005
YELLOW
4.2
PART No
65166/002
RED
4.3
PART No
65166/003
BLUE
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
ALTERNATIVE COMBINATION
4.4
PART No
65166/004
GREEN
4.5
PART No
65166/005
YELLOW
PACK
THICKNESS
COLOUR
4.2
PART No
65166/002
RED
4.3
PART No
65166/003
BLUE
8.4
8.5
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 2
43
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
14. Gearbox (Optional)
The gearbox incorporates a cooling system, which utilises cold water diverted
from the main pump body to flow around the gearbox outer housing and then
return to the pump. The water is always flowing around the gearbox whenever
the pump is operating and pumping water. This section describes the gearbox
when it is in a vertical position in relation to the pump body, other positions are
possible.
The gearbox incorporates an oil filling point , an oil level check point and an oil
drain point for the routine maintenance of the unit. These points are duplicated
on both sides of the gearbox to allow for different installation arrangements.
There is also an oil drain point at the front of the mounting platform, if a
platform is fitted.
The oil capacity of the gearbox is approximately 1.2 litres. The photograph
below shows the left side of the gearbox as viewed from the PTO end.
Oil filling
Oil level
point
Oil drain point
check
Oil drain point
The gearbox must be filled with approximately 1.2 litres of the recommended
oil before any operation commences. The recommended oil is BP Energol GR
XP 68. If this is not available, the following may be used – Elf Reductelf SP
68, Shell Omala 68 or equivalent.
Undo the oil filling and level check plugs with a suitable spanner. Ensure no
dust or debris enters the gearbox when the plug is removed. Using a funnel,
pour the oil into the gearbox housing until it overflows from the check level
plug. Before replacing the plugs, apply Loctite 572 to the plug threads to
ensure a good seal, replace and hand tighten with a suitable spanner.
The oil level can be checked by removing one of the oil level check point
plugs, located on both sides of the gearbox, see the photograph above. The
oil should be just up to the lower rim of the hole, which indicates the capacity
is approximately 1.2 litres. This is the only accurate method of checking the oil
level as it allows for different size gear ratios.
44
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Before replacing the plug, apply Loctite 572 to the plug thread to ensure a
good seal, replace and hand tighten with a suitable spanner.
The gearbox oil should be changed completely every 250 running hours or
annually, whichever is sooner.
These diagrams show the oil fill
points, oil level check points and oil
drain points for the gearbox in the
three different positions available –
down, left or right.
Oil fill
Oil level check
Oil drain
DOWN OPTION
Oil fill
Oil fill
Oil level
check
Oil level check
Oil level
check
Oil drain
Oil drain
The gearbox cooling system requires no regular maintenance. If the pump
needs to be drained for any reason, there is a drain located at the lowest point
in the cooling system. To drain the system, either remove the plug, or, if
connected to a remote drain, open the remote drain cock. Allow all water to
completely drain away before replacing the plug or closing the remote drain
cock.
Before replacing the drain plug, apply Loctite 572 to the plug thread to ensure
a good seal, replace and hand tighten with a suitable spanner.
45
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
15. Water Ring Primer (Optional)
The Water Ring Primer is available as an alternative to the Piston Primer
system. It is mounted above the bearing housing and driven by a fibre wheel
(47) in contact with a pulley at the end of the main pump shaft. Operation of
the Water Ring Primer is fully automatic, when the pump is started the primer
is driven by the pulley wheel turning the fibre wheel, air is evacuated from the
pump allowing water to enter and build water pressure inside the volute. The
water pressure inside the pump is then used, via the redundant piston primer
housing, to act on a lever which pivots, and through a second lever (61), lifts
the Water Ring Primer clear of the drive pulley on the pump shaft. When the
primer disengages from the pulley it stops operating, if the pump pressure
falls e.g. when the pump is turned off, the primer fibre wheel will re-engage
with the pulley ready for priming operation when the pump is started again.
To Remove
To remove the entire Water Ring Primer unit, slacken the hose clip (19)
retaining the 3/4inch hose to the top of the primer. Disconnect the hose and
secure the hose end away from the primer. Disconnect and remove the primer
return spring (62) from the lower part of the primer. If connected, remove the
air outlet connection from the top and the water inlet connection from the
bottom of the primer. Slacken the two screws (79, 80) securing the primer to
the hinge pin (69). Carefully ease the primer unit off the primer hinge pin.
Maintenance
To dismantle the primer for internal inspection, remove the 10 bolts (38)
securing the primer bearing housing (54) to the primer body (1). Remove the
primer bearing housing complete with shaft, bearings, impeller and pulley.
Examine the inner diameter of the impeller (12) and the corresponding surface
of the suction and delivery cover (6) for excessive scoring, renewing these
parts if necessary.
To fit a new suction and delivery cover (6), remove the self-locking screws (7)
which secure the cover plate (5) to the suction and delivery cover (6). Fit this
cover plate to the new part, noting that no gasket is used but jointing
compound should be used on the contacting faces.
To fit a new impeller (12), undo the impeller retaining screw (10) and pull off
the impeller.
Note: if the impeller binds on the shaft it will be necessary to remove the
primer shaft as follows At the pulley end of the shaft, knock back the tabwasher (49) and remove the
nut (50) securing the pulley to the shaft. Remove the pulley and extract the
woodruff key (41) and the circlip (46). Tap out the shaft (40) from the impeller
end. The shaft will bring the bearings (42, 45) with it and these can now be
replaced if necessary. The shaft seal (13) will remain in position and if this
requires renewing it should be drifted out, together with its backing washer
(14), towards the impeller end.
46
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
47
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
When fitting a new seal ensure that the lip on the backing washer and the
open end of the seal face is towards the impeller.
To fit a new friction drive pulley (47), remove the pulley from the shaft as
detailed above, undo the four nuts, bolts and washers (51, 52, 53) securing
the pulley to the centre piece. Fit the new pulley. Refitting of the pulley
assembly is a reversal of the dismantling instructions. Ensure that a new tab
washer (49) is always used on re-assembly.
To examine the non-return valve on top of the primer, undo the four bolts and
washers retaining the priming valve inlet (20) to the valve body (26) and cover
(30). Examine the seals (23, 25), spring (27) and diaphragm (30) for wear, if
necessary replace these parts.
To Refit
When refitting the water ring primer, rotate the primer hinge pin from its
original position so that the two screws (80) will bear on a different part of the
shaft. Move the whole primer forwards or backwards until both sides of the
primer fibre wheel bear equally on the sides of the driving pulley on the pump
shaft. Tighten the screws and the associated locknuts. Reconnect the hoses
to the relevant points and refit the primer return spring.
When the primer is in position it is important to set a 3mm gap between the
bottom of the lift-off pad (58) attached to the primer and the lift-off rod which is
used to lift the primer away from the drive pulley. The gap is to make
allowances for a new fibre drive wheel to “bed-in” through initial wear, but still
maintain sufficient distance to allow the lift-off mechanism to work correctly.
The lift-off pad can be turned to move it up or down as required.
When water ring primer is in engaged
position (fibre pulley is resting in drive
flange) there must be 3mm gap
between lift-off pad on primer and
cylinder piston below.
48
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
16. Pump Tests
Vacuum Test
Place the blanking cap(s) in position on the inlet(s) of the pump and close the
delivery valves. Run the pump at 1300-1500 rpm and observe the
vacuum/compound needle. When a vacuum of 0.81bar is obtained, stop the
pump. This vacuum should be maintained for at least 15 seconds or drop no
more than 0.07bar in a minute.
If the pump will not hold the vacuum with the blanking caps in position, a leak
is present in the pump, and the pressure test detailed below must be carried
out to trace it.
Should the pump not reach a vacuum of 0.81bar but will hold a lower
pressure, a fault in the priming system is indicated.
Pressure Test
This test is to be carried out if the pump will not hold a vacuum with blanking
cap(s) in position, and is intended to trace the leaks responsible for the loss of
vacuum.
Apply a water pressure of 3.5 - 7.0 bar to the pump and check for leaks. The
area causing the leak should be visible, and can be dismantled and rectified.
Check each primer drain hole for water leakage. If leakage is found, replace
the primer seals and O rings as described in the Maintenance Manual
Procedures.
If the pump will not achieve 0.81 bar vacuum, and will not hold what it does
achieve, there is a leak, and possibly also a fault, in the priming system.
If no leaks are apparent, the leakage must lie between the priming valve and
the primer. Points to be checked are:
The inlet seal in the primer end cap
The priming valve diaphragm
Water Ring Primer (optional priming system)
If a water ring primer is fitted carry out the same vacuum test as described
above but run the pump at 2300rpm to achieve a vacuum.
Should the pump not reach a vacuum of 0.78bar but will hold a lower
pressure, a fault in the priming system is indicated. Check as follows –
See that the primer drive (fibre pulley) is engaged with the pump pulley and
runs without slipping
Check that the primer is filled with water
Check the primer seal drain hole for leakage. If leakage is found, fit a new
seal to the primer.
If the pump will not hold a vacuum apply the pressure test (as above) and
check for leaks. Defective joints and seals must be replaced. If no leaks are
apparent, the leakage must be in the line from form the priming valve to the
49
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
water ring primer, points to be checked are the priming valve sealing washer,
the water ring primer non-return valve and the rubber hose and clip.
Pressure Relief Valve (PRV) and Thermal Relief Valve (TRV) Test
With the pump primed, and HP operation selected, close all discharges. Run
the pump at approximately 2800rpm. The HP stage pressure should not
exceed 50bar if the PRV is working satisfactorily.
Continue running the pump, to permit it to heat up. The TRV should open and
discharge water when the pump temperature is about 48°C (for a Standard
42°C TRV, for a 74°C it will open about 80°) . Observe the discharge, if it
open to atmosphere, or feel the discharge pipe become warm if it returns to
the vehicle tank. Open a pump discharge valve to permit cool water to enter
the pump. The flow from the TRV should now cease.
If the TRV is not operating as it should follow this procedure –
Thermal Relief Valve Maintenance
The Thermal Relief Valve (TRV) fitted usually requires minimum maintenance
attention, but should the valve be failing to open at the specified temperature
or remaining open after the water temperature has lowered, follow these
instructions to clean the valve.
1. Location. The TRV is located on the top surface of the discharge manifold –
2. Remove the TRV with a suitable adjustable spanner to grip the main TRV
body.
50
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
3. Remove the internal parts from the outer housing. Secure the TRV
vertically in a vice. With an adjustable spanner undo the top part of the TRV.
4. The TRV internal parts will now slide out of the housing
5. The thermal actuator (p/n 57053) can now be pushed out of the main
housing from the cone end for inspection
Thermal
actuator,
p/n 57053
51
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
6. All the main internal parts can now be inspected for wear and/or the buildup of mineral deposits.
If there is significant deposit build-up, this can be removed by cleaning the
outer housing and internal parts in a proprietary lime scale remover.
Housing
p/n 60806
Seal
p/n UFP2303/10
Elbow
p/n 59392
O ring
p/n 51894
inside cone
thermal actuator sleeve
spring
O ring
p/n 57053
p/n 60808 p/n 670715 p/n 58107
outlet adaptor
p/n 60807
Build-up of deposit,
usually due to high
concentration of
mineral deposits in
water
Faulty operation could be due to the sleeve (p/n 60808) sticking in a closed or
open position on the outlet adaptor (p/n 60807). Also, if the O rings (p/n
58107) are worn or damaged there will be an inadequate seal allowing water
to discharge unnecessarily.
7. Re-assembly is a reversal of the dismantling process. If new O rings (p/n
58107) are to be fitted, roll the first O ring into the lower groove on the outlet
adaptor, then roll the second O ring over the first O ring in to the second
groove higher up the adaptor. Apply water resistant grease to the new O rings
and the grooves to facilitate fitting.
NB: Service Parts Required – Seal, UFP2303/10, 1 off. O ring, 58107, 2 off.
Fit this
O ring
first
Fit this O ring
second
Cross section
of assembled
TRV
52
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
17. Delivery Valves
Ball Valve Type
The ball valve should not be dismantled unless it is functioning
unsatisfactorily. There are two possible faults and the method of correcting
them is as follows:
1. Water leaking round the ball
This is due to the O Ring not pressing tightly enough against the ball. Remove
the bolts and spring washers and separate the coupling end tube from the ball
valve housing. Turn the O Ring over so that it presents a new face to the Ball
Valve, or fit a new O Ring. Rub a little Molybdenum Disulphide Powder into
the surface of the ball where it contacts the O Ring. Leave the original
washers or the same thickness of new washers, between the faces of the
coupling end tube and the valve housing.
In the case of old valves which have seen extremely arduous service, it may
be necessary to fit a new ball, pivot or valve stem. To do this, remove the
screw securing the valve stem cap to the ball valve housing and lift off the
handle assembly.
Remove the nut on the underside of the valve housing and push the ball pivot
pin towards the centre of the ball. Remove the spring and take out the two
half-rings securing the valve stem. Push out the valve stem and withdraw the
ball. Fit the new part required and reassemble, reversing the above
procedure. Use a right angled screwdriver to hold the pivot pin when
tightening the pivot pin nut. Ensure that the handle is fitted in the correct
position. Fit the stem O Ring and ensure that the two half rings are correctly
positioned.
2. Water leaking up the valve stem
If this occurs, remove the handle and stem as in "1" above and fit a new valve
stem O Ring, rubbing a little molybdenum Disulphide Powder into the bore of
the valve stem cap.
53
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
1
2
3
4
5
6
7
8
Valve Stem
Valve Stem Seal
Valve Housing
Ball Valve
Ball pivot and Spring
O Ring
Coupling End Tube
Coupling Release Bolt
Part
Nos
LH
RH
9
10
11
12
13
14
15
Spring
Coupling Release Cap
Release Cam
Closure Disc
Operating Handle
Circlip
Joint Washers
Light Alloy Gunmetal
I/C
I/C
TH137
TH153/100
TH138
TH154/100
54
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Screw-down Type
Godiva Part Number 56544/01 Light Alloy and 56544/05 Gunmetal
(Instantaneous Connector Versions)
Pump Delivery Valve 2 1/2" Female
Instantaneous (single twist) to BS336
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
Main Body
Inlet
Outlet
Pivot Pin
O Ring
Circlip
Screw Down Handle
Domed Nut
Spring Washer
O Ring
Screw Down Spindle
Roll Pin
Non Return Flap
Non Return Flap Washer
Item
15
16
17
18
19
20
21
22
23
24
25
26
27
Description
Retaining Washer
Washer Insert
Instantaneous washer
Twist Release Knob
Release Cam
Release Spring
Release Plunger
Knob Closure Disc
Nyloc Nut
O Ring
Countersunk Screw
Plain Washer
Moly Grease
Twice Yearly Servicing Procedure, Full Assembly:
A. Check that Screw Down Spindle "11" rotates freely. Regrease with Lithium
EP2+Moly Grease (as supplied by Pennine Lubricants).
B. Check that Non-Return Flap "13" is free to articulate and that Washer "14"
is undamaged. Regrease Pivot Pin "4".
C. Check O Rings "10", "5" and "24". Replace where necessary.
55
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Continental Delivery Valves
1
3
4
4.1
5
6
7
8
9
10
11
12
13
14
Body, incl. Nipple
Spindle
Guide Sleeve
O-Ring
X-Ring
Guide Axle Complete
Tap Washer
Valve Plate Complete
Tap Washer
Compression Spring
Release Knob Assembly
Handwheel
Washer
Cap Nut
56
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Function
The valve opens and closes by turning the handwheel anti-clockwise and
clockwise respectively and has an integrated, automatic non-return device.
The handwheel should be opened until the spindle travels against the stop
and then twisted half a turn in the opposite direction.
When the pump is temporarily stopped, the non-return valve keeps the
delivery hose filled and prevents the water in the hoses from draining via the
pump inlet.
To drain filled delivery hoses, especially when hoses are connected to a dry
riser at buildings,
pull Release Knob (11). The handwheel may now be
turned further in the opening direction and water is allowed to drain via the
pump.
Maintenance
The spindle should be greased (lubricated) on a quarterly basis, using a
proprietary waterproof grease such as Shell Retinex A or equivalent.
Caution
When opening the valve do not force the handwheel against its stop. NB.
Max. working pressure is 16bar.
57
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
Instantaneous Connector Servicing Procedure:
1
2
3
4
5
6
7
8
9
Knob Closure Disc
Twist Release Knob
Twist Release Cam
Twist Release Bolt
2 1/2" Inst Seal
2 1/2" Twist Release Body
Nut
Coil Spring
Self-Lock Pin
Inspection
A. Flush out equipment with clean water after use
B. Inspect equipment monthly and follow maintenance procedures at least
once every year
C. Inspect release mechanism for free movement
D. Inspect the rubber seal
Maintenance
If signs of wear or breakdown of the mechanism occur, strip down and replace
parts as follows:
1. Remove Knob Closure Disc "1". If the disc is of plastic type, insert pointed
tool into hole in disc and prise out. If the disc is metal, use an Ajax ladder
key locating in the 2 holes in the disc and unscrew anti-clockwise.
2. Unscrew nut "7" using a socket spanner and Knob "2" can then be
removed.
3. Withdraw Bolt "4" and Spring "8" from the inside of the female
instantaneous body.
4. Check for signs of dirt, wear or corrosion of the Spring, clean the parts and
reassemble. If wear has occurred replace the affected parts with spares.
5. Reassemble the mechanism by reversing the foregoing instructions using
a lubricating grease on the Spring and the Bolt.
6. When tightening Nut "7" the tension on the spring is correct when the
leading edge of the curved face of Bolt "4" is level with the bolt hole edge
as shown in Dia. B above.
7. Check Seal "5" for dirt, cuts or damage to seal lip after cleaning. If
damaged, replace with spare seal.
Special Notes
 The recommended lubricant for the bolt and spring is Molybdenum
Disulphide Grease (Lithium Grease)
 Always use a new locknut when reassembling the mechanism.
58
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
17. Tightening Torques
Part
Description
Torque
Nm
Lbs ft
MS164/20
NPN
65019/001 Seal Housing to Clutch Stator
65017/004 Friction plate to eccentric drive. (Clutch
manufacturers supply)
65094 Seal housing to bearing housing
65040 Cover plate to pump head
65004 Rear wear ring to cover plate
65078 Front wear ring to suction tube
Impeller retaining nut
Drive flange retaining screw
Screw retaining piston primer to yoke in bearing housing
20
28
15
21
20
44
10
12
300
103
20
15
32
7.5
9
225
76
15
MS166/25
MS165/35
65405
MS164/25
65181
MS07/35
65169
18. Special Tools
Part
For Piston Primer Equipped Pumps
Description
60275/03
65486
65239
65240
65436
65466
65467
Clamping spacer
Mechanical seal extraction tool
Piston seal assembly tool – cone locator
Piston seal assembly tool – seal expander
Circlip fitting tool – piston primer seal replacement
Cylinder support tool – piston primer seal replacement
Circlip drift - piston primer seal replacement
Part
For Water Ring Primer Pumps
Description
60275/03
65486
Clamping spacer
Mechanical seal extraction tool
59
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.
19. Adhesives, Solvents and Greases List
The following is a summary of the adhesives, solvents and greases required
and the area of application.
Page reference
Location
Adhesive
12
Front wear ring, securing
to suction tube
Loctite 243. Tighten to
12Nm.
14
Inside
bore
of
pressure impeller
Tallow
15
Rear wear ring, securing
to pump head or cover
plate
Loctite 243. Tighten to
12Nm.
18
HP cover plate, auto drain
ball plate, 2 off screws
Loctite 243
18
HP cover plate to pump
body, under head of
capscrews
Molykote 37. Tighten to
44Nm
19
Mechanical
seal
assembly, inserting into
pump head or impeller
Soft soap solution
25
Piston primer – screw
retaining inlet and outlet
valves
Loctite 380e
28
Piston primer – o ring
(52816) on piston shaft
General purpose grease
31
Piston to yoke,
screws
Loctite 243. Tighten to
20Nm
34
Bearing housing. Fitting
bearings to shaft, 2 off.
Tallow
35
Seal housing to clutch
stator
Loctite 243. Tighten to
20Nm.
37
Clutch rotor to shaft, inner
surface. Early type of
assembly only.
Loctite 638
39
Clutch friction plate to
eccentric drive, 3 off
screws
Loctite 243. Tighten to
28Nm
42
Seal housing to bearing
housing, 6 off cap screws
Loctite 243. Tighten to
20Nm
44, 45
Gearbox – drain plugs, oil
level check plugs
Loctite 572
52
TRV – o rings on actuator
Water resistant grease
53
Delivery valve, ball type.
Valve ball and stem.
Molybdenum
powder
57
Delivery valve,
continental type. Spindle
Shell Retinax
equivalent
58
Instantaneous connector
bolt and spring
Molybdenum Disulphide
grease (Lithium grease)
low
2 off
disulphide
A
or
60
©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.